Method for forming, filling and sealing a container having plural closures

ABSTRACT

A unitary, hermetically-sealed dispensing container, having plural removable closures and suitable for containing and dispensing sterile solutions, is provided. The removable closures are unitary with the container. The dispensing container comprises a sealed, elongated shell of thermoplastic material provided with at least one access port at each end of the shell, a neck portion unitary with the shell and surrounding each access port, and removable cap means over the access ports and joined to the corresponding neck portions by means of frangible annular webs. The frangible annular webs are unitary with the cap means and with the neck portions. At least one of the neck portions is provided with a bore of predetermined controlled dimensions and is adapted to receive a draining spike or a similar means for withdrawing the contents of the container.

BACKGROUND OF THE INVENTION

This invention is directed to unitary dispensing containers, and to a method for the fabrication of such containers.

Packaging systems that blow-mold, fill and seal containers such as bottles, bags, and the like, enjoy widespread commercial acceptance because of ease of fabrication and reduced labor costs. Moreover, such a packaging system obviates the need for costly auxiliary equipment that cleans and handles empty containers, fills the containers, and subsequently seals the filled containers. A packaging system of the foregoing type is disclosed in U.S. Pat. No. Re. 27,155 to Hansen.

Since the complete filling cycle for a container takes place in an enclosed environment when the aforementioned form, fill and seal packaging system is employed, this system is well-suited for sterile and aseptic packaging of parenteral solutions and the like substances. However, for such solutions it is desirable to provide a container having an access aperture of controlled dimensions that can receive a draining spike without undesirable leaking when it is desired to drain the container contents. For non-collapsible containers it is also desirable to provide a venting aperture provided with an outwardly projecting stem or boss of controlled outside dimensions so that an air filter can be conveniently mounted thereon when the container contents is drained.

Heretofore, it has not been possible to consistently attain the requisite dimensional control in a unitary blow-molded container, particularly for internal dimensions. The present invention, however, provides unitary dispensing containers having access apertures and unitary, externally projecting members of predetermined, relatively closely controllable dimensions.

SUMMARY OF THE INVENTION

The present invention provides a unitary, hermetically sealed dispensing container having a plurality of access apertures of controlled internal and/or external dimensions and sealed by means of removable closures that are unitary with the container. The container comprises a hollow, generally tubular body or shell of thermoplastic material closed at both ends. The container is provided at one end with a first access aperture surrounded by a first hollow stem means or neck portion unitary with the container and having a bore of predetermined configuration, and at the other end with a second access aperture surrounded by a second hollow stem means or neck portion unitary with the container and having an outer side surface of predetermined configuration. First and second removable closure means, unitary with the respective hollow stem means, and joined thereto by means of annular frangible webs, hermetically seal the container until such time when the container contents is to be withdrawn.

Each removable closure means can be provided with a unitary tab means so as to facilitate the removal of the closure means.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings,

FIG. 1 is a front elevational view showing a dispensing container embodying the present invention;

FIG. 2 is a side elevational view of the dispensing container shown in FIG. 1;

FIG. 3 is a bottom view of the dispensing container shown in FIG. 1;

FIG. 4 is a fragmentary sectional view, on an enlarged scale, taken along plane 4--4 in FIG. 2;

FIG. 5 is a fragmentary elevational view, on an enlarged scale, depicting one end of the container shown in FIG. 1 after this container has been opened;

FIG. 6 is a fragmentary sectional view, similar to the view shown in FIG. 4, but depicting the container at an intermediate fabrication stage; and

FIGS. 7-10 are partial sectional views generally illustrating the method of forming, filling and sealing containers.

DESCRIPTION OF PREFERRED EMBODIMENTS

Referring to FIGS. 1 and 2, dispensing container 10 can be made utilizing the general blow-forming, filling and sealing techniques taught in U.S. Pat. No. Re. 27,155 to Hansen. However, these techniques are modified in certain respects, as will be discussed in detail hereinbelow, in order to make possible fabrication of containers embodying the present invention.

Container 10 comprises a hollow, generally tubular body or elongated shell 11 closed at both ends and defines a sealed enclosure. At upper end 13 of container 11 is provided a container neck portion in the form of first hollow stem or collet 12 surrounding access aperture 30 (FIG. 4) and suitable as a contents-filling and/or withdrawing port. Collet 12 is unitary with shell 11, is provided with bore 31 having a predetermined configuration, e.g., a controlled inside diameter and/or cross-section, and at the distal end thereof is removably closed with cap 14 unitary with collet 12. Cap 14 is joined to collet 12 by means of a frangible web 31 (FIG. 4) that is unitary with cap 14 as well as with collet 12. Cap 14 is provided with tab 15, unitary with cap 14 and shell 11, for facilitating the removal of cap 14 from collet 12. In the embodiment shown in FIGS. 1 and 2, tab 15 is generally L-shaped and is larger than cap 14 in order to provide for easy gripping and leverage when container 10 is opened by twisting off cap 14. After opening, upper end 13 of container 10 assumes the configuration shown in FIG. 5 with the open end of collet 12 ready to accept a draining spike.

If desired, and in order to minimize the likelihood of an inadvertent and premature removal of cap 14, tab 15 is connected to shell 11 by means of a substantially coplanar, relatively thin, frangible web 16 that is readily broken as tab 15 is twisted.

While container 10 can be filled during the fabrication thereof through bore 31 of hollow stem or collet 12, for a relatively larger container the filling time, and thus total fabrication time, can be considerably reduced by providing an auxiliary filling aperture. Such an aperture can be aperture 29, defined by filling aperture neck portion or collet 17, which is permanently sealed after container 10 has been filled to the desired extent, for example, by permanent cap 18 that is molded unitary with collet 17.

Lower end 19 of container 10 is provided with an access aperture, suitable as a venting aperture or the like, surrounded and defined by a neck portion such as hollow stem or collet 20 which has a predetermined outer side surface configuration and which terminates in a unitary but removable sealing cap 21, joined to stem 20 by means of frangible web 28. If desired, sealing cap 21 can be provided with grippable tab 25 for easy removal.

The dimensions of the outer side surface of stem 20 can be controlled during fabrication of the container, as will be discussed in detail hereinbelow, so that stem 20 can accept and frictionally hold an air filter housing or a similar appurtenance. Preferably stem 20 is slightly tapered toward its distal end.

During the dispensing of parenteral solutions, container 10 is usually situated in an inverted position. In order to provide an integral hanger hole for this container, container lower end 19 can be bifurcated during fabrication so as to provide paired pockets 22 and 23 that are bridged by unitary sleeve member or tubular connector 24 which, in turn, defines a confined flow passageway between pockets 22 and 23 and, together with portions of the container walls defining pockets 22 and 23, also defines hanger hole 25.

Inasmuch as during storage container 10 normally is in an upright position as shown in FIGS. 1 and 2, it is desirable to build into the container bottom some substantially planar surface on which the container can rest. To this end, the distal portions of pockets 22 and 23 can be flattened to provide substantially coplanar lands such as the substantially triangular lands 26 and 27 illustrated in FIG. 3.

In order to permit the upright storage of container 10 in instances when sealing cap 21 is provided with a tab means such as tab 25, tubular connector member or sleeve 24 is spaced inwardly from the plane defined by lands 26 and 27, and hollow stem 20 is made unitary with sleeve 24. The dimensions of stem 20, cap 21 and tab 25, as well as the spacing of sleeve 24 from the plane defined by lands 26 and 27, of course, is selected so as to allow container 10 to rest on lands 26 and 27 when in an upright position.

As further illustrated in FIG. 4, access aperture 30 at the upper end 13 of shell 11 serves as a container contents-withdrawing aperture and is surrounded by collet 12 which serves to hold means for withdrawing the container contents. Bore 31 in collet 12 is of a predetermined inside diameter and is adapted to receive and frictionally engage in a sealing relationship a draining spike or similar draining means. Bore 31, and thus aperture 30, are removably sealed by cap 14 that is connected to collet 12 via frangible annular web or weakened flange 33.

A further access aperture, suitable for filling the container, is illustrated by aperture 29 surrounded by collet 17 and permanently closed, after filling, by means of cap 18 unitary with collet 17. As pointed out before, a filling aperture such as aperture 35 is not necessary for containers of relatively small capacity inasmuch as such containers can be readily filled during fabrication via the access aperture that ultimately serves as the container contents-withdrawing aperture. However, the filling rate for larger containers can be substantially increased if an additional filling aperture, larger than the contents-withdrawing aperture, is utilized.

Rigidity of relatively large containers can be enhanced by providing rigidifying ribs or indentations in the side walls thereof. To this end rigidifying indentations such as grooves 34 and embossments 35 are provided in the side walls of container shell 11.

To fabricate the dispensing containers of the present invention, any blow-moldable thermoplastic material compatible with the product to be packaged can be utilized. Typical illustrative thermoplastic materials that are suitable are the usual blow-molding grade materials such as high-density polyethylene, low-density polyethylene, polypropylene, and the like.

Containers embodying the present invention can be readily fabricated by blow molding and filled utilizing the general forming, filling and sealing technique disclosed in U.S. Pat. No. Re. 27,155 to Hansen, the disclosure of which is incorporated herein by reference to the extent pertinent, as modified by certain refinements described hereinbelow. Further description of the general fabrication technique, and in particular the technique for making weakened flange connections, i.e., the frangible webs, that join the removable closure means to their respective collets or stems can be found in U.S. Pat. No. 3,597,793 to Weiler et al. and is incorporated herein by reference to the extent pertinent.

In general, the fabricating apparatus includes a parison extruder, a mold comprised of movable mold portions for forming the main body portion of the container (including the bottom part thereof), the container neck portion, and the sealing cap portions, holding jaws for retaining a segment of an extruded parison in a predetermined position with respect to the various mold portions, parison cutting means, and a mandrel for blow-forming the container and then filling the container. Associated with the mandrel are means cooperating with the mold portions forming the container neck portion or collet to provide a weakened flange connection between the container neck portion and a unitary sealing cap or similar closure means for the container.

In particular, and as described in detail in said U.S. Pat. No. 3,597,793, the present method can be practiced utilizing the apparatus generally disclosed in U.S. Pat. No. Re. 27,155 and also shown in FIGS. 7-10. This apparatus 50 includes an extruder 52, a two-piece mold 54 including mold halves 54a and 54b, a holding jaw 56 including jaw halves 56a and 56b, a head jaw 58 including jaw halves 58a and 58b, a cutting apparatus 60, and a composite filling and blow tube 62. For a full and detailed description of the apparatus 50, reference can be made to the above-mentioned U.S. Pat. No. Re. 27,155. Generally, however, the operation is as follows. A parison in the form of a hollow tube 64 is extruded by the extruder 52, between the mold halves 54a and 54b. When the parison or tube 64 is of the required length, the mold halves 54a and 54b are closed. The lower end of the tube 64 is pinched closed by the mold, and its upper end is positioned and held by the holding jaw 56, through the application of vacuum applied thereto, and is separated by the cutting apparatus 60, which may be a heated wire. A mold carriage (not shown) moves the mold 54, the holding jaw 56 and the head jaw 58 into position for shaping, filling and sealing the container.

To fill the container, the mandrel 68 of the composite filling, blowing and notching tube 62 moves into the conical neck part 66, and the hot plastic tube 64 is inflated by a burst of compressed air and pressed against the walls of the mold 54. At the same time, a precisely metered quantity of the product being bottled fills the container via a filling channel (not shown) in the mandrel 68 by a precise metering machine (not shown). The air used for inflating or blowing the container is discharged to the outside through an air discharge duct (not shown). As soon as the product hits the plastic walls, the container solidifies.

The mandrel 68 is raised, and the jaw halves 58a and 58b of the head jaw 58 are closed by means of two cylinders (not shown). The head jaw 58 forms and seals the upper container head, and thereafter the mold 54, the head jaw 58 and the holding jaw 56 all open. The filled and hermetically sealed containers leave the apparatus via a container dropout chute (not shown).

To fabricate a container in general, a parison in the form of a hollow tube is extruded from the extruder and situated between the movable mold portions when the latter are in an open position. When a required length of the parison has been extruded, the mold portions for forming the main body portion of the container (sometimes also called the lower mold portions) are closed about the extruded parison so as to pinch together and close the lower end of the extruded parison and to constrict the upper end of the parison portion confined within the closed mold portions. The mold portions forming the container neck portion may be separately movable or they may be unitary with the mold portions for forming the main body portion of the container. At substantially the same time parison holding jaws are moved into position so as to grasp the upper end of the extruded parison and to hold the same in an open position while a predetermined length of the extruded parison is severed and the main body portion of the container is formed and subsequently filled.

To form and then fill the formed container, a mandrel that includes a blowing tube and a filling tube is positioned within the open end of the extruded parison so as to pinch a peripheral constricted portion of the open end against the now-closed mold portions and provide a substantially gas tight seal therebetween. Thereafter, that portion of the extruded parison situated within the cavity defined by the closed mold portions is inflated by a burst of gas, e.g., air or the like, and pressed against the walls of the mold cavity. At substantially the same time, a metered quantity of the intended container contents is introduced into the inflated parison portion that has assumed the configuration of the container body as a result of the aforementioned inflation. The introduced container contents usually is at a relatively lower temperature than the parison and assists in solidifying the walls of the formed container. At about the same time, the gas utilized to inflate the container is discharged to the outside through appropriate venting ducts provided in the mandrel for that purpose.

After the formed container has been filled to the desired degree, the mandrel is withdrawn from the open end of the parison and the container sealed by the action of mold portions for forming the container closure, i.e., the upper mold portions, which are brought together and pinch shut the open end of the parison. Thereafter all mold portions, as well as the holding jaws, open and the formed, filled and sealed container drops out or is removed from the fabricating apparatus.

To form weakened flange connections between the container neck portion and the container closure means, the mandrel in the apparatus generally described hereinabove is provided with means that cooperate with the mold portions that form the container neck portion or collet together with a base portion of the closure means as described in detail in the aforementioned U.S. Pat. No. 3,597,793 to Weiler et al.

To fabricate the containers embodying the present invention, the mold portions and the mandrel are specially designed to provide for substantially simultaneous compression molding of the container neck portion or collet with a bore having predetermined inside dimensions. For this purpose, the mandrel is provided with an elongated compression molding member that enters the constriction formed in the extruded parison by either neck portion mold parts that are integral with the lower mold parts or by auxiliary, separately movable neck portion mold parts that are associated with the lower mold parts, and compression molds a bore within the container neck portion or collet before the formed container is filled and capped.

A dispensing container embodying the present invention can be formed, filled and sealed using an open assembly of mold parts that define a container-forming cavity and that are provided with means for constricting a predetermined portion of a parison. A parison of a thermoplastic material is then extruded between the open assembly of mold parts as a semi-solid, elongated, hollow tube, and the mold parts are closed about the parison so as to confine a portion therebetween and within the container-forming cavity. One end of confined parison portion is pinched closed, and the other end of the confined parison portion is deformed so as to provide a constriction with an access aperture into the confined parison portion.

Thereafter a predetermined length of the extruded parison is severed so as to provide an open-ended parison portion that is unitary with the confined parison portion and extends above the latter. Severing of the parison can be readily achieved using a wire cutter means or the like while the parison is held between vacuum-assisted holding jaws in a known manner.

After a predetermined length of the extruded parison has been severed, the formed access aperture is temporarily sealed with a mandrel equipped with an elongated, extensible compression molding member and with an annular molding surface that coacts with the mold parts so as to form a weakened flange. The mandrel is applied to the constriction surrounding the access aperture so that the weakened flange is formed about the constriction between what ultimately becomes the container neck portion or collet and the base portion of the cap means.

Thereafter the elongated compression molding member is extended into the constriction to form a container neck portion or collet having a bore of predetermined configuration and communicating with the access aperture. The produced bore is adapted to receive and engage in a sealing relationship a draining spike or a similar implement for withdrawing the contents of the container.

The confined parison portion is blow-formed into a container conforming to the configuration of the mold cavity by pressurizing the confined parison portion either through the aforementioned access aperture or through a second aperture provided in the confined parison portion in a similar manner as the mold parts are closed about the parison. The second aperture can also have associated therewith a compression-molded neck portion, if desired. The formed container body is filled with a desired contents utilizing either or both of the aforementioned access apertures.

When the forming and filling operations are completed, the mandrel is removed from the constriction, closure forming mold parts are provided about the open-ended parison portion and operated so as to form a closure for the compression-molded bore that is joined to the container neck portion by the weakened flange.

By way of example, the formation of a collet having a bore of controlled inside diameter is shown in FIG. 6. In this particular embodiment lower mold part 32 is machined to provide container body cavity 36 and inwardly-extending peripheral flange 37 capable of constricting open end 38 of the extruded parison and serving also as the mold part for forming the container neck portion or collet. Grooves 45 and 46 in flange 37 are adapted to form a base portion for unitary caps 18 and 14, respectively.

In this particular example, flange 37 is shaped so as to cooperate with a corresponding flange on the mold part opposing mold part 32 and to pinch together predetermined opposite portions of the extruded parison in central region 38 thereof, thereby substantially simultaneously providing apertures 29 and 30 in upper end 13 of container shell 11.

The desired inside dimensions for bore 31 of collet 12 are produced by the action of elongated compression molding member or ram 39 that is carried within mandrel 40. Ram 39 can be extended from within mandrel 40 so as to enter and shape bore 31. Preferably ram 39 is cylindrical; however, ram side surface 41 can be machined to any desired cross-section, e.g., round, triangular, square, etc., and the ram can have any desired configuration, e.g., straight, tapered, stepped, or the like.

As illustrated in FIG. 6, mandrel 40 is also provided with an annular, ring-shaped molding surface 42 that serves to form frangible annular web 33 around collet 12 as taught in the aforementioned U.S. Pat. No. 3,597,793 to Weiler et al. If desired, mandrel 40 can also be equipped with container blowing and filling nozzles that are coaxial with ram 39 in which case aperture 30 can serve the dual functions as a filling aperture and as a container contents-withdrawing aperture. However, in such cases the filling nozzle has a relatively small opening and for containers having a capacity in excess of about 10 milliliters the filling rate becomes a factor limiting the container production rate. Accordingly, for the fabrication of relatively larger containers it is preferable to provide an auxiliary filling aperture such as aperture 29 surrounded by collet 17 that is compression molded by mandrel 44 to the desired configuration. Mandrel 44 comprises blowing tube 45 that terminates in ring-like molding ram 46, which determines the inside dimensions for the bore of collet 17, and filling tube 47 situated within blowing tube 45 and in a telescoping relationship therewith.

Mandrels 40 and 44 are brought into open end 38 of the extruded parison, preferably substantially simultaneously in order to minimize fabrication time. However, mandrels 40 and 44 can be actuated individually, if desired.

After collets 12 and 17 have been formed, mandrels 40 and 44 are withdrawn and the filled container is sealed by the action of appropriate mold parts as taught in U.S. Pat. No. Re. 27,155 to Hansen and U.S. Pat. No. 3,597,793 to Weiler et al. The tabs, such as tab 15 for cap 14 can be conveniently molded during the container sealing operation by providing appropriate cutting edges in the mold parts that are brought together to pinch closed open end 38 of the extruded parison. Frangible coplanar web 16 that serves as securement means for tab 15 can also be molded at the same time, if desired, by providing an appropriate mold protuberance of projecting edge which gives the desired configuration for web 16, for example, as shown in FIG. 4.

The dimensions and configuration of the external side surfaces of hollow stem or collet 20 at lower end 19 of container 10 (FIGS. 1, 2 and 3) are determined by the dimensions of the corresponding mold cavities in the lower mold portions. Vacuum passages usually are provided in the lower mold portions that define the cavity for collet 20 so as to permit the necessary control of the outside dimensions thereof.

The foregoing specification and the drawings are intended as illustrative and are not to be taken as limiting. Still other variations within the spirit and scope of this invention are possible and will readily present themselves to one skilled in the art. 

We claim:
 1. A method for forming, filling and sealing a container made from a thermoplastic material which comprises the steps ofproviding an open assembly of mold parts defining a container-forming cavity and provided with means for constricting a parison; extruding between said mold parts a parison of said thermoplastic material in the form of a semi-solid, elongated hollow tube; closing said assembly of mold parts about said parison so as to confine a portion thereof between said mold parts and within said container-forming cavity while pinching closed one end of the confined parison portion and deforming the other end of said confined parison portion to provide a constriction defining a pair of access apertures into the confined parison portion; severing a predetermined length of the extruded parison so as to provide an open-ended parison portion above the confined parison portion and unitary therewith; temporarily sealing one of said access apertures by applying to the deformed parison portion defining said one access aperture a first mandrel equipped with an elongated, extensible compression molding member and with an annular molding surface coacting with said mold parts so as to form a weakened flange about said one access aperture; extending said compression molding member into said one access aperture so as to form a container neck portion having a bore of predetermined configuration and communicating with said one access aperture; temporarily sealing the other of said access apertures by applying to the deformed parison portion defining said other access aperture a second mandrel equipped with a blowing tube and a filling tube and terminating in a ring-like molding ram so as to form a second container neck portion having a bore of predetermined configuration and communicating with said other access aperture; blow-forming said confined parison portion through said blowing tube so as to produce a container body conforming to configuration of said mold cavity; filling the formed container body with a desired contents; removing both of said mandrels from said deformed parison portions; positioning closure-forming mold parts about said open-ended parison portion; and operating said closure-forming mold parts so as to form individual closures for both of said access apertures unitary with said container body.
 2. The method according to claim 1 wherein said first and second mandrels are applied substantially simultaneously.
 3. The improvement in accordance with claim 1 wherein said elongated compression molding member is substantially cylindrical and provides a bore having a substantially circular cross-section. 